Adjustable wall stud

ABSTRACT

A wall stud which includes opposed mounting surfaces for receiving wall panels, a web is disposed between the opposed mounting surfaces, and the stud has first and second ends. The first end is provided on a first stud member and the second end is provided on a second stud member. The first and second stud members are moveable with respect to one another to provide for adjustment of the effective length of the wall stud.

This application is a continuation of U.S. application Ser. No. 14/344,948 filed Mar. 14, 2014 which is a National Stage completion of PCT/AU2012/001120 filed Sep. 19, 2012 which claims priority from Australian application serial No. 2011903918 filed Sep. 23, 2011.

TECHNICAL FIELD

The present invention relates to wall studs and particularly to those used for constructing internal partition walls.

BACKGROUND TO THE INVENTION

Currently, the most popular way to build a non load bearing wall, such as a partition wall, is using steel stud and track. First, horizontal top and bottom tracks are secured in place at the desired locations of the top and bottoms of the partition wall. Then vertical studs are installed at regular intervals between the top and bottom tracks.

Studs are obtained which have a length longer than the height of the wall to be constructed. The studs must then be cut to length. The distance between the top and bottom tracks is measured, the measurement is transferred to the stud and the stud is cut. Depending on the levels of the floor and ceilings, this process could be duplicated for every stud. If however the levels are accurate, one measurement is taken and every stud is cut to the same length. The most common method for cutting studs to length is using tin snips. The process of measuring and cutting wall studs is very time consuming.

There remains a need for improved components and methods for constructing walls.

SUMMARY OF THE INVENTION

In a first aspect the present invention provides a wall stud including: opposed mounting surfaces for receiving wall panels; a web is disposed between the opposed mounting surfaces; first and second ends; the first end is provided on a first stud member and the second end is provided on a second stud member; the first and second stud members are movable with respect to one another to provide for adjustment of the effective length of the wall stud.

The second stud member may be a sliding fit within the first stud member.

The end of the second stud member may be arranged to have the same effective external dimensions as the end of the first stud member.

The end of the second stud member may include projections which provide the same effective external dimensions as the end of the first stud member.

The wall stud may further include fixing means for fixing the first and second stud members in position.

The fixing means may include a ratchet and pawl arrangement which permits lengthening of the stud, but resists shortening of the stud.

The pawl may be provided in the form of a flap that is integrally formed with the web of one of the stud members.

The ratchet and pawl arrangement may include a pair of pawls.

The ratchet and pawl arrangement may include a ratchet formation in the form of a series of slots provided in the web of one of the stud members.

The ratchet formation may include two series of slots which are provided side by side.

In a second aspect the present invention provides a method of constructing a wall including the steps of: installing upper and lower wall tracks, each including a trough for receiving the ends of wall studs; providing a series of wall studs according to the first aspect of the invention; adjusting the effective lengths of the wall studs to fit between the upper and lower tracks; and installing the wall studs in the tracks.

In a third aspect the present invention provides a method of constructing a wall including the steps of: removing wall studs from a wall constructed in accordance with the second aspect of the invention; and readjusting the effective length of the wall studs.

BRIEF DESCRIPTION OF THE DRAWINGS

An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1A is a front view of a wall stud according to an embodiment of the invention;

FIG. 1B is a right side view of the wall stud of FIG. 1A;

FIG. 1C is a rear view of the wall stud of FIG. 1A;

FIG. 1D is a left side view of the wall stud of FIG. 1A;

FIG. 2A is a left side view of the lower stud member of the wall stud of FIG. 1A;

FIG. 2B is a front view of the lower stud member of FIG. 2A;

FIG. 2C is a right side view of the lower stud member of FIG. 2A;

FIG. 2D is a cross sectional view along the line A-A of FIG. 2C;

FIG. 2E is a perspective view of the lower stud member of FIG. 2A;

FIG. 2F is an enlarged view of Detail B of FIG. 2A;

FIG. 2G is an end view from the lower end of the of the lower stud member of FIG. 2A;

FIG. 3A is a left side view of the upper stud member of the wall stud of FIG. 1A;

FIG. 3B is a front view of the upper stud member of the wall stud of FIG. 3A;

FIG. 3C is a right side view of the lower stud member of FIG. 3A;

FIG. 3D is a cross sectional view along the line D-D of FIG. 30;

FIG. 3E is a perspective view of the upper stud member of FIG. 3A;

FIG. 3F is an enlarged view of Detail F of FIG. 3A;

FIG. 3G is an end view from the lower end of the upper stud member of FIG. 3A;

FIG. 4A is a cross sectional view along the line H-H of FIG. 4B;

FIG. 4B is a right side view of the wall stud of FIG. 1A shown in the fully extended configuration;

FIG. 4C is a rear view of the wall stud of FIG. 4B;

FIG. 4D is a left side view of the wall stud of FIG. 3B; and

FIG. 4E is an enlarged view of detail G of FIG. 4A.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIGS. 1A to 1D, a wall stud 10 is shown including a first stud member in the form of lower stud member 20 and a second stud member in the form of upper stud member 30. The bottom end 22 of stud 10 is provided on lower stud member 20. The top end 32 of stud 10 is provided on upper stud member 30. Stud 10 includes front 12 and rear 14 mounting surfaces which, following installation of the stud, receive plasterboard wall panels by affixing the panels to the front and rear surfaces of the stud 10 by use of appropriate fasteners in a known fashion. The front and rear surfaces of the stud are provided with closely spaced grooves or ripples in a known fashion to improve the ease of engagement of screw fasteners.

A web 15 extends between the front 12 and rear 14 faces of the stud 10. Bell mouthed service holes 16 are provided at intervals along web 15 which, when installed, are used to route cables and pipes and other conduits in a known fashion.

The first 20 and second 30 stud members are formed from galvanised sheet steel of approximately 0.7mm thickness. Second stud member 30 is a sliding fit inside first stud member 20. The stud members 20, 30 are moveable with respect to one another in a telescopic fashion under control of a ratchet and pawl mechanism which allows the effective length of the stud 10 to be increased, but resists shortening of the length of the stud 10 as will be later described. In FIGS. 1A to 0, the stud 10 is shown in its fully retracted configuration.

Referring to FIGS. 2A to 2G lower stud member 20 is shown in isolation and includes a ratchet formation in the form of two series of slots 24. As seen best in Detail C, slots 24 are formed by punching out flaps 26 from web 25 of the lower stud member. The slots 24 are the gaps created at the lower edges of flaps 26.

Referring to FIGS. 3A to 3G upper stud member 30 is shown in isolation and includes a pair of pawls which, as best seen in Detail E, are formed by punching out flaps 36 from web 35. The flaps 36 are dimensioned to fit into slots 24.

To assemble the stud 10, the upper end 32 of the upper stud member 30 is inserted into the lower end 22 of the lower stud member 20. The upper stud 20 member is then slid upwards inside the lower stud member 20. This movement necessitates inward compression of pawl flaps 36 which have an innate degree of springiness by virtue of being integrally formed from the steel of the web 35. When the pawl flaps 36 are aligned with the lowermost pair slots 24 the flaps 36 spring outwardly. In this position, the stud 10 is assembled and is in its fully retracted position as shown at FIGS. 1A to 1D.

The pawl flaps 36 resist shortening of the effective length of stud 10 by engagement with the slots 24. It is possible however to increase the effective length of the stud 10 by sliding the upper stud member upwardly with respect to the lower stud member. During this movement, the pawl flaps 36 move up the series of slots 24. Whenever the flaps 36 align with a higher pair of slots 24, the pawl flaps 36 spring outwardly to engage with the slots and the upper member becomes set at that height.

The ratchet and pawl mechanism has a degree of backlash. That is to say, when the pawl flaps 36 align with a pair of slots 24 and spring outwards, the upper stud member 30 is then pushed down a short distance to properly engage the flaps 36 with slots 24 (as shown best in FIG. 4E). The amount of backlash roughly corresponds to the vertical length of the pawl flaps 36.

The resolution of the degree of adjustment of the length of stud 10 is defined by the spacing of the slots 24. More closely spaced slots provide for a greater number of positions in which the stud members can be locked together for a given overall length of adjustment.

The overall length of adjustment is defined by the length of the ratchet formation, being the length of the series of slots 24. A convenient degree of adjustment suitable for constructing office partition walls would be from about 2050 mm to about 2750 mm.

Referring to FIGS. 4A to 4E, the stud 10 is shown in its fully extended configuration in which the pawl flaps 36 are engaged with the uppermost pair of slots 24. As previously explained, the ratchet and pawl mechanism does not allow the effective length of the stud to be shortened again. However, should it be desirable to make the stud shorter in length, then this can be achieved by pulling the upper stud member 30 fully out of the lower stud member 20 and re-inserting it into the lower end of the lower stud again as was described for the process of assembling the stud 10. This allows the effective length of the stud to be adjusted again.

To construct a partition wall using studs 10, upper and !ower tracks are installed in a conventional manner. The tracks include troughs for receiving the upper and lower ends of the wall studs. To install a stud 10 between the tracks, the stud is offered up to the tracks and the effective length of the stud is adjusted to the maximum length that will fit between the upper and lower tracks. The width of the troughs in the tracks is roughly equal to the distance between the front and rear faces 12, 14 of the stud 10. To fit the stud into place it is typically rotated slightly about the axis of its length and its ends are located in the upper and lower tracks. The stud 10 is then rotated about its length to snap into position in the troughs with its front and rear faces pressed against the front and rear troughs. Construction of the partition wall then proceeds in a conventional manner.

Referring again to FIGS. 3B and 3D, protrusions 37, 38 are pushed out of the front and rear face of the upper stud member. These are provided to compensate for the slight size difference between the upper and lower stud members that is necessitated by one being sized to fit inside the other. The protrusions 37, 38 mean that the outside dimensions of the second end of the stud 10 are effectively the same as the outside dimensions of the lower end of the stud in the region of the front and rear faces where they engage with the tracks.

Because stud 10 is adjustable in length, it is able to be reused, or reconfigured at a later date.

Although the stud was described above in the scenario of constructing a partition wall, it can be used to construct other installations such as bulkheads.

The thickness of the wall being constructed is a function of the width of the web of the stud. Variations of studs can be produced with variously sized webs to construct was of a variety of thicknesses.

It can be seen that embodiments of the invention have at least one of the flowing advantages:

A wall can be constructed without the need to measure and cut studs, thus saving time and trouble.

The stud can be readjusted in length. This allows reconfiguration or reuse of studs and thus prolongs their useful life, reducing waste.

Any reference to prior art contained herein is not to be taken as an admission that the information is common general knowledge, unless otherwise indicated.

Finally, it is to be appreciated that various alterations or additions may be made to the parts previously described without departing from the spirit or ambit of the present invention. 

1-12. (canceled)
 13. A wall stud comprising: opposed mounting surfaces for receiving wall panels; a web is disposed between the opposed mounting surfaces; first and second ends; the first end being provided on a first stud member and the second end being provided on a second stud member; the first and second stud members being movable with respect to one another to provide for adjustment of an effective length of the wall stud; and the wall stud further including fixing mechanism for fixing the first and second stud members in position; wherein the fixing mechanism includes a ratchet and pawl arrangement which permits lengthening of the stud, but resists shortening of the stud; the pawl is provided in the form of a flap that is integrally formed with the web of the second stud member; the ratchet and pawl arrangement includes a ratchet formation in the form of a series of slots provided in the web of the first stud member; and the second stud member has a sliding fit within the first stud member.
 14. The wall stud according to claim 13, wherein the second end of the second stud member is arranged to have a same effective external dimensions as the first end of the first stud member.
 15. The wall stud according to claim 14, wherein the second end of the second stud member includes projections which provide a same effective external dimensions as the first end of the first stud member.
 16. The wall stud according to claim 13, wherein the ratchet and pawl arrangement includes a pair of pawls.
 17. The wall stud according to claim 13, wherein the ratchet formation includes two series of slots which are provided side by side.
 18. A method of constructing a wall including the steps of: installing upper and lower wall tracks, with each of the upper and lower tracks including a trough for receiving the ends of wall studs; providing a series of wail studs; each of the wall studs comprising opposed mounting surfaces for receiving a wall panel; a web is disposed between the opposed mounting surfaces; each wall stud has first and second ends; the first end is provided on a first stud member and the second end is provided on a second stud member; and the first and second stud members are movable with respect to one another to provide for adjustment of an effective length of the wall stud; forming at least one flap integrally with the web of the first stud member; forming a ratchet formation as a series of slots along the web of the second stud member; providing the second stud member so as to have a sliding fit within the first stud member; engaging the first and the second stud members with one another; sliding the first stud relative to the second stud to adjust the effective lengths of the wall studs to fit between the upper and the lower tracks; engaging the least one flap of the web of the first stud member with at least one desired slot along the web of the second stud member to lock the first stud member relative to the second stud member and retain the adjusted effective length of the wall stud; and installing each of the adjusted wall studs in the tracks.
 19. The method of constructing a wall including the steps of: removing wall studs from a wall constructed in accordance with claim 18; and readjusting the effective length of the wall studs.
 20. A wall stud comprising: opposed mounting surfaces for receiving wall panels; a web is disposed between the opposed mounting surfaces; first and second ends; the first end being provided only on a first stud member and the second end being provided on only a second stud member and the first stud member being different from the second stud member; the first and second stud members being movable with respect to one another to provide for adjustment of an effective length of the wall stud; and the wall stud further including fixing mechanism for fixing the first and second stud members in an adjusted position relative to one another; wherein the second stud member has a sliding fit within the first stud member so as to facilitate sliding movement of the first stud member relative to the second stud member and adjustment of the effective length of the stud; the fixing mechanism includes a ratchet and pawl arrangement which only permits lengthening of the stud, but resists shortening of the effective length of the stud; the ratchet and pawl arrangement includes a pawl provided as a flap that is integrally formed in the web of the first stud member; and the ratchet and pawl arrangement includes a ratchet formation in the form of a series of slots formed in the web of the second stud member. 